Composite floor and deck covering structure



Jan. 16, 1968 H. B. WAGNER ET AL 3,3

COMPOSITE FLOOR AND DECK COVERING STRUCTURE Filed Jan. 16. 1964INVENTORS. HERMAN B. WAGNER DAVID s. WEIANT WxWV ATTYS United StatesPatent 3,364,658 COMPOSITE FLOOR AND DECK COVERING STRUCTURE Herman B.Wagner, Perlrasie, and David S. Weiant, Philadelphia, Pa, assignors toSelby, Battershy & Co., Philadelphia, Pa., a cnrporation of DelawareFiled Jan. 16, 1964, Ser. No. 343308 11 Claims. (Cl. 117-40) Thisinvention relates to a traffic-bearing composite floor and deckcovering, and more particularly to a completely monolithic and seamlesspermanent deck and floor covering which is not affected by snow and ice,and which permits normal movement of the substructure or base supportwithout damage thereto.

A covering for sub-floor or base support is subjected to many stresses.For example, the sub-floor may shrink and expand with temperaturechanges. In the case of wood sub-floors, ordinarily there is additionalshrinkage and expansion due to changes in humidity. Such shrinking andexpansion subjects the covering to stresses of a magnitude which mayproduce cracks in the covering. If moisture can penetrate these cracks,additional damage may result, particularly where the covering is subjectto freezing and thawing conditions.

Considerable effort has been made to provide a floor and deck coveringwhich is not subject to damage by reason of movement of the subfloor.These efforts have resulted in systems where the covering is madesomewhat elastic and is separated from the sub-floor so that thesubfioor can move relative to the covering. One such means of separationcomprises a felt under-layer which is attached to the sub-floor alongthe periphery of the floor and at spaced points within the interiorfloor area.

A major problem with the use of felt as the separating means between thesub-floor and covering has been cracking at the corners where the feltis bonded directly to the sub-floor as well as to the covering and whereboth the covering and the sub-floor are subjected to lateral as well aslongitudinal movement.

A primary object of this invention is to provide a trafficbearingcomposite floor and deck covering which permits normal movement of thesubstructure supporting it to take place without harm to the covering.

Another object of this invention is to provide a seamless permanent deckand floor covering which is tough, durable and fire-retardant.

A further object of this invention is to provide a monolithic compositefloor and deck covering which can be applied to a wide variety of areas,such as old leaking sundecks and useless roof areas, to provide anattractive and useful floor.

.Still another object of this invention is the provision of a compositefloor and deck covering which is waterproof and free from costlymaintenance such as caulking, etc.

Yet a further object of this invention is to provide a dry mix, whichwhen combined with water, produces a construction material which isparticularly useful in providing a release coating which permitsrelative movement between the wear surface of a floor and deck coveringand a sub-floor, whereby the covering is not subjected to damagingstresses due to normal movement of the subfloor.

These and other objects of this invention will become further apparentfor a consideration of this specification, claims and accompanyingdrawing.

The figure of the drawing is a diagrammatic perspective view,substantially enlarged, showing a composite floor and deck coveringaccording to this invention.

In accordance with this invention there is provided a floor and deckcovering for use on a sub-floor or base support comprising a relativelythin release coat applied as a plastic mass over the base support andwhich upon setting forms a substantially non-tacky, solid layer havingan indentation characteristic of less than above 50% four hours afterapplication and a shear strength of not more than about 2.5 p.s.i. sevendays after application; and a relatively thicker wear coat over saidrelease coat.

Referring now to the figure in the accompanying drawing, there isillustrated at 10 a base support or subfloor, which may be of plywood,wood, quarry tile, concrete slabs, steel or any other construction whichis strong enough to support the anticipated load. The base support orsub-floor should be provided with a relatively smooth surface, free ofpits, holes and loose materials. In addition to being sound, the basesupport should be free of such materials as oil, grease, paint, etc.

Superimposed on the base support 10 is a release coat, generallyindicated at 12. The purpose of the release coat is to permit relativemovement between the base support or portions thereof and the wear andwaterproofing layers in the floor and deck covering construction of thisinvention. In this manner the wear and waterproofing layers are isolatedfrom movement of the substructure and are not subject to stresses aswould cause damage thereto, such as cracks, spalling, etc.

The release coat preferably comprises a composition which can be appliedto the base support by unskilled workmen as a plastic mass, as bytrowelling. Preferably, it may comprise a composition having as themajor constituent an inorganic cementitious material, and also willcontain inorganic filler and a release agent.

To permit application of the wear coat, and also a waterproofing coat ifdesired, over the release coat, without undue delay after application ofthe release coat, the release coat should solidify in a relatively shortperiod of time, for example, in about 2 to 4 hours, and after becominghard should have sufficient compressive, indentive and tensile strengthto support workmen applying the overlayer or layers without anysubstantial rupture or cracking. For this purpose an indentationcharacteristic at the end of four hours of less than about 50% isdesirable, an indentation characteristic of less than about 30% at theend of four hours being preferred. All values for indentationcharacteristic given in this specification and appended claims are basedon the method of determination identified in the art as MIL-D-3134FSpecification of Jan. 24, 1962. This specification is more fullydescribed hereinafter in connection with the several specific examples.In addition to having sufficient strength to permit completion of thecovering without damage, the release coat should be substantiallynon-tacky.

As stated previously, the release coat functions to isolate themovements of the sub-floor from the covering so that the former mayexpand and contract without damage to the latter. To provide for suchisolation, the release coat should rupture at a relatively low shearstress, to release the wear and any waterproofing coats from thesub-floor. In other words rupture of the release coat takes place whenthe stresses created by movement of the subfloor and/ or covering exceeda given minimum value. It was found that to obtain the desired release,shear strength seven days after application should be less than about2.5 p.s.i. as determined by the equation:

shear strength= 9 a ing (wear layer, moisture proof layer, etc.), 1 isthe thickness of the covering layer or layers (release layer notincluded), and l is one-half the length of the sample being tested, thesample being one inch in width.

Shear strength as determined by the above Formula 1 may be derived fromdata obtained from apparatus comprising a surface having two separablehalves. A test sample one inch in width comprising a release coat andwear coat (as well as other over-layers, e.g. a waterproofing coat) isplaced in the apparatus so as to be equally divided on both halves ofthe separable surface areas. The halves are then separated and thedistance between the two halves (the value of d in Formula I) isdetermined when the release coat permits separation of the wear layerfrom the test apparatus. The presence or absence of cracks in the wearlayer at the time of release is also noted.

The modulus of elasticity (m in Formula I) of the release coat used incalculating shear strength, may be determined by measuring deformationvs. stress in a Scott tester using sample portions of the test sample.The method by which modulus of elasticity may be determined is morefully described in connection with the specific examples hereinafter setforth.

Although the release coat may vary considerably in the thickness, itshould be of relatively uniform thickness throughout its entire extent,and preferably should range in thickness from about 0.025 to about 0.035inch. If the release coat is substantially less than 0.025 inch it maybe discontinuous in certain areas, and in these areas there may be atendency for the immediate over-layer, e.g. a waterproofing layer, toadhere to the sub-flooring, thereby impairing the floating action of thefloor covering. At such points of contact stresses which will damage thecovering may be set up even under ordinary movement of the sub-flooring.If the release layer has a thickness which is substantially in excess of0.035 inch, the time required for the release layer to set to permitapplication of the over-layers may be considerably increased andapplication costs may thereby be increased.

As stated above, the release coating preferably comprises as the majorconstituent an inorganic cementitious material which can be applied as aplastic mass. Preferably, the cementitious material will comprise suchsubstances as calcined gypsum, lime and hydraulic cement. By the termhydraulic cement is meant any of the wellknown construction cements suchas magnesium oxychloride cement, Kuhl cement, Portland cement, aluminouscement, pozzolanic cement, special activator cements, etc.

The release coat, in addition to inorganic cementitious material, maycontain an organic release agent. The purpose of the release agent is tolower the shear strength of the release layer to such a level as willpermit rupture thereof when subjected to movements of the sub-floorand/or floor covering. The organic release agent may comprise anymaterial which obtains this result without adversely afiecting otherproperties of the release coat, such as compressive strength,indentation characteristic, etc., to such a level that the coating istoo weak or fragile to permit the subsequent application of the wear andwaterproofing layers.

Typical of the organic release agents which may be used in the releasecoat of this invention are anionic surface active agents, paraffinwaxes, polymer emulsions such as polyethylene emulsions, and silicones.The anionic surface active agents, particularly the alkyl and alkyl arylsulfonates, and metal salts of fatty acids, are preferred release agentsaccording to this invention.

The alkyl and alkyl aryl sulfonates used in this invention have theformula or alkyl aryl containing from 12 to 20 carbon atoms. and X ishydrogen, alkali metal and alkaline earth metal.

Suitable alkyl sulfonates are: sodium and potassium octyl, nonyl, decyl,hendecyl, dodecyl, tridecyl, tetradecyl, hexadecyl, octadecyl sulfonate.A preferred alkyl sulfonate comprises sodium dodecyl sulfonate.

Alkyl aryl sulfonates which may be used are those derived from benzene,naphthalene, diphenyl and diphcnylmethane, and include among others:sodium and potassium hexyl, heptyl, octyl, nonyl, decyl, hendecyl,dedecyl, tridecyl, and tetra-decylbenzene sulfonate. As with the alkylsulfonates, the alkyl group in the alkyl aryl sulfonates 'may compriseeither a straight or branched chain. A preferred alkyl aryl sulfonatecomprises sodium dodecylbenzene sulfonate.

The salts of fatty acid which may be used in this invention have theformula where R is alkyl containing from 8 to 18 carbon atoms and X ishydrogen, alkali or alkaline earth metal.

Typical compounds of this type are the sodium and potassium salts ofsuch fatty acids and capric, undecylic, lauric, tridecoic, hydristic,pentadecanoic, palmitic, margaric, stearic, nondecyl, and arachidicacid.

The inorganic release agent may also comprise a waxy solid hydrocarbonof the paraffin series containing from 10 to about 30 carbon atoms.

The release coat or layer may also contain a linear silicon resin as arelease agent. Such silicon resin preferably has a molecular weight inthe range between about 250 and 2000.

The amount of release agent which may be incorporated in the releaselayer may vary considerably; however, ordinarily the weight ratio ofinorganic cementitious material to release agent will be in the rangebetween about 6:1 and about 20:1, a weight ratio in the range betweenabout 8:1 and about 12:1 being particularly preferred.

In addition to inorganic cementitious material and release agent, therelease coat may contain a finely divided inorganic filler having anaverage particle size in the range about 25 and about 325 Examples ofsuitable inorganic fillers are fine sand, silica flour, pow= deredcalcium carbonate, powdered barium sulfate, ground cinders, and finelydivided perlite or vermiculite. The inorganic filler may be present inthe release coat in an amount up to about 50%, by weight, of theinorganic cementitious material. Preferably, the inorganic filler ispresent in an amount from about 10 to about 20%, by weight, of inorganiccementitious material.

Sufiicient water should be added to the solid con stituents to providethe mixture with a consistency per mitting relatively easy uniformapplication to the sub floor, as by trowelling. Ordinarily the amount ofwater used should be such as to provide the composition with a slump offrom about 4 to about 11 inches, as determined by ASTM designation(3143-58 entitled Slump of Portland Cement Concrete. A preferred slumpis one of approximately 10.25 inches.

For the purpose of providing the floor or deck coat ing withwaterproofing characteristics where the con'' struction may be subjectedto Water, as in exterior decks, there is applied over the release coat12, a waterproofing coat generally indicated at 14 in the figure in theaccompanying drawing. This layer essentially comprises a textile fabric,such as burlap, impregnated and coated with rubber.

In applying the waterproofing coat 14, preferably the release layer 12is covered with a rubber latex to a thickness when wet of approximatelyinch. Application of the rubber latex may be by means of a trowel, alittle at a time, so that while the latex is still wet a textile fabricmay be embedded in and fully wetted by the latex.

The textile fabric may be composed of organic or inorganic fibers andmay be either woven or non-woven. A preferred fabric for use in thisinvention which provides adequate strength at reasonable cost is burlap,a 7 /2 oz. burlap being a particularly suitable fabric. The burlap orother fabric should be applied as strips and should overlap each other,an overlap of two to four inches being generally satisfactory. To theexcess amount of rubber latex that works through the fabric while it isbeing embedde, additional latex should be added, as by trowelling, intothe fabric surface. The amount of latex used should be sufiicient tofill all pinholes so that the upper surface of the fabric comprises acontinuous rubber film free of holes. In order to insure completecoverage of the fabric with latex, it is preferable to apply a secondcoat of rubber latex to the upper surface of the fabric after the firsthas dried. The thickness of the waterproofing layer may be from about 35to about 100 mils. a thickness of about 60 mils being generallysufiicient for good waterproofing.

As stated above, the purpose of this layer comprising rubber coated andimpregnated textile fabric is to provide waterproof characteristics tothe composite floor and deck covering where the covering will be exposedto moisture. This waterproofing layer can, however, be omitted where thefloor construction need not have waterproof properties.

In the present application the term rubber is used. This term as usedherein is intended to include not only natural rubber, but also anyartificial or synthetic rubber. For certain purposes some of thesynthetic rubbers may be preferable to natural rubber by reason of theirresistance to chemical attack, for example by oils and greases. Of thesesynthetic rubbers a polymerized chlorine derivative of 1,3-butadiene,which is sold under the trademark Neoprene is presently preferred. Theterm latex as used herein in connection with rubber is intended to meanan aqueous dispersion of any rubber as herein defined. As such,therefore, these terms are used in their broadest conventional sensethroughout the present specification and claims. The rubber latex may,if desired, contain conventional vulcanizing agents and/or vulcanizationaccelerators.

The next layer above the waterproofing layer 14 is the wear coat and isindicated at 16. The composition of the wear layer comprises hydrauliccement and rubber latex. The hydraulic cement in the composition 16 ispresent in an amount sufficient to substantially dehydrate the latexused and thereby provide a relatively rigid composition as finally driedand cured. This composition also contains a suitable mineral filler asaggregate, preferably a hard igneous rock, such as andesite, having agrain a particle size of about 16 to about 60 mesh. This wear coat isapplied over the entire floor or deck area and may have a thickness ofabout As" to about Depending upon the desired thickness of the wearcoat, it may be applied as a single coat or a plurality of coats, thesecond being superimposed on the first after the first has dried.

The wear coat is initially plastic and has a consistency permittingrelatively easy application as by trowelling.

For many purposes, the construction hereinabove described issatisfactory. However, the top surface may be enhanced in appearance byapplying thereto a relatively thin coating of a resin composition.Suitable resins for this purpose are vinyl resins, such as polymers andcopolymers of vinyl chloride and vinylidene chloride, epoxy resins,polyurethane resins, acrylic resins and the like. Such resin compositionmay contain pigments to provide the top coat With a pleasant color. Thetop coat also provides a smooth finish and acts as a seal.

The resin compositions employed as a top layer may also contain aplasticizer and a. filler, in addition to a coloring agent. Theproportions of the ingredients may vary considerably depending upon thedensity and flexibility required and the ype of resin, plasticizer andfiller used. In general the most satisfactory compositions for use asthe wear resisting layer of floor coverings contain about 25% to 50% byWeight of resin and from about 6 10% to 30% of a plasticizer, thebalance being filler and pigment.

Various advantages of this invention may be seen by reference to thefollowing examples, which are merely illustrative of the invention andare not in any way intended to limit the scope of the invention.

In the examples of the shear stress data for the release layer wasdetermined by means of extension apparatus comprising a surface 40" inlength and 16" in width, divided into two halves. By means of a screwmechanism the two halves can be separated, In the examples each testsample comprised a strip 1" wide and 20" long. Each test sample wasplaced in the extension device perpendicular to the line of separationof the two halves, so that equal portions of the sample were disposed oneach half.

Each test sample comprised the following layers:

(1) A release coat approximately & thick for providing relative movementbetween the surface of the extension apparatus and the superimposedwaterproofing, wear and top coats.

(2) A waterproofing coat approximately 0.06" thick comprising a 7 /2 oz.burlap impregnated with a polychloroprene latex containing vulcanizingconstituents.

(3) A wear coat approximately 0.125" thick comprising polychloroprenelatex, vulcanizing constituents for the latex, cement and fine aggregatehaving an average particle size of between 30 and 250 mesh, and

(4) A top coat approximately .010 thick comprising plasticizedpolyvinylchloride.

The release coat, wear coat and top coat were applied by means of atrowel. The waterproof coat was applied to the release coat bytrowelling polychloroprene latex over the release coat, applying theburlap thereto, and then trowelling addition polychloroprene latex overthe burlap to insure that all of the interstices of the burlap werefilled with latex. Approximately 3 hours were permitted to lapsesubsequent to application of the release coat and prior to applicationof the waterproofing coat.

Seven days after application of the above-described coatings to thesurface of the extension apparatus, it was opened at a rate ofapproximately mils per minute. The width of the opening between the twohalves was measured when the release coat provided release, i.e. firstpermitted relative movement between the coats superimposed on therelease coat and the supporting release coat applied on the surface ofthe extension apparatus. Shear strength for the release coat was thendetermined by means of Formula I, discussed above.

In determining shear strength according to Formula I, the modulus ofelasticity (m) may be obtained using a Scott Tension Test machine. Indetermining modulus of elasticity for use in calculating shear strengthfor the release layer in the following specific examples, samples offloor covering comprising a Waterproofing layer, a wear layer and a toplayer (see layers 14, 16 and 18, respectively of the drawing) eightinches long by two inches wide were placed in the jaws of the Scotttester. The distance between the jaws was 6 inches. The samples weresubjected to a load of 70* lbs. and the increase in length under thisload was measured using calipers. Modulus of elasticity was thencalculated by means of the equation:

where m is themodulus of elasticity, l is the initial distance betweenclamps before application of load, L is the load applied to thespecimen, d is the elongation in inches and A is the cross sectionalarea of the test specimen.

In the examples the modulus of elasticity obtained was the average oftests on several test specimens. In the examples the modulus ofelasticity for each sample was determined to be approximately 8300p.s.i.

In the below examples, initial and final set data are Gilmore Needle SetTimes obtained according to ASTM Designation C 26658T. Indentationcharacteristics were determined according to the procedure described inMILD3134F Compressive strength data was obtained according to ASTMDesignation C 109-58 entitled, Compressive Strength of Hydraulic CementMortars.

The method by which indentation characteristic for the several exampleswas determined is set forth in MILD 3134F dated Ian. 24, 1962. In thisstandard method for determining indentation an hydraulic press and anindentor are required. Three indentations were made on each sample andthe results averaged. The center of each indentation was not less than1% inches from the edge of the test specimen and not less than 2 /2inches from the center of the adjoining indentation. A load of 2000 lbs.was applied for 30 minutes by a flat faced circular indentor having anarea of one square inch and a perimeter rounded to a radius of inch.

The release coat was applied to a flat steel plate A thick and 6" x 6"in size so as to obtain a smooth flat surface. An Ames type thicknessgauge was used to measme the thickness of the steel plate and thecombined thickness of the steel plate and applied release coat. Afterthe prescribed indentation for /2 hour, the amount of indentation wasdetermined and percent indentation calculated.

In the below examples, no changes were made in the compositions of theseveral coats, with the exception of the release coat, which is noted inthe examples. The several coats were applied in the same manner toapproximately the same thickness in each of the examples.

Example I The release coat had the following composition:

Water-40 g. per 100 g. of solids.

An initial set of the release coat was obtained in 89 minutes and afinal set was obtained in 145 minutes. The indentation characteristic ofthe release layer was 65% after 4 hours and 65% after 7 days. Thecompressive strength for the release coat (standard 2" x 2" blocks) was288 p.s.i. after 15 days, and 345 p.s.i. after 30 days.

A release coat of the above composition was tro-welled onto the surfaceof the extension apparatus described above to a uniform thickness ofapproximately & The waterproofing, wear and top coats hereintoforedescribed were then applied and the composite was permitted to set for aperiod of seven days. The extension apparatus was then activated, therate of separation between the two halves being approximately 100 milsper minute. Release by the release coat was obtained when the two halveshad been separated 0.5 in.

Shear strength after 7 days was determined to be 1.30 p.s.i. The coatingsystem was free of cracks.

Example 11 Example I was repeated with a base coat having the followingcomposition:

Water-40 g. per 100 g. of dry solids. The system had the followingproperties:

Set: Minutes Initial 95 Final 160 8 Indentation characteristics: PercentAfter 4 hours 18.2 After 6 hours 15.1 After 7 days 15.1 Compressivestrength: P.s.i. After 15 days 240 After 30 days 320 Release:

0.625" after 7 days.

Shear strength:

After 7 days, 1.60 p.s.i.

Condition of top coat:

Free from cracks.

Example 111 Example I was repeated with a base coat having the followingcomposition:

Constituent: Weight percent Sodium lauryl sulfate 8 Calcined calciumsulfate 52 Silica flour (125 mesh) 40 Water-40 g. per g. of dry solids.

The system had the following properties:

Shear strength:

After 7 days, 1.52 p.s.i.

Condition of top coat: Free from cracks.

Example IV Example I was repeated with a base coat having the followingcomposition:

Constituent: Weight percent Sodium lauryl sulfate 10 Calcined calciumsulfate 82 Silica flour (125 mesh) 8 Water-40 g. per 100 g. of drysolids.

The system had the following properties:

Set: Minutes Initial 94 Final Indentation characteristics: Percent After4 hours 26.4 After 6 hours 25.0 After 5 days 25.0

Compressive strength: P.s.i. After 15 days 200 After 30 days 325Release:

0.594 after 7 days.

Shear strength:

After 7 days, 1.53 p.s.i.

Condition of top coat:

Free from cracks.

9 Example V Example I was repeated with a base coat having the followingcomposition:

Constituent: Weight percent Sodium lauryl sulfate l2 Calcined calciumsulfate 72 Silica flour (125 mesh) 8 Water-40 g. per 100 g. of drysolids. The system had the following properties:

Release:

0.625" after 7 days.

Shear strength:

After 7 days, 1.6 p.s.i.

Condition of top coat: Free from cracks.

Example VI The procedure of Example I is repeated using the compositionof that example, with the exception that the sodium lauryl sulfate isreplaced by sodium octadecyl sulfonate, and similar releasecharacteristics are observed.

Example VII The procedure of Example I is repeated using the compositionof that example, with the exception that the sodium lauryl sulfate isreplaced by sodium dodecyl benzene sulfonate, and similar releasecharacteristics are observed.

Example VIII The procedure of Example I is repeated using thecomposition of that example, with the exception that the sodium laurylsulfate is replaced by sodium laurate, and simi-. lar releasecharacteristics are observed.

What is claimed is:

1. A traffic-bearing composite floor and deck covering which permitsrelative movement between the wear surface thereof and the supportingsubfioor, whereby said wear surface is not subjected to damagingstresses due to movement of the sub-floor, comprising a relatively thinrelease layer capable of being ruptured when subjected to stressescreated by relative movement between said subfioor and said wear surfaceto isolate said wear surface from the movement of said sub-floor appliedas a plastic mass over a sub-floor so as to be substantially coextensivetherewith and which upon setting forms a substantially non-tacky, solidlayer having an indentation characteristic of less than about 50% fourhours after application and a shear strength of not more than about 2.5p.s.i., seven days after application, and a relatively thicker wearlayer over said release layer which is applied as a plastic mass andupon setting comprises hydrated hydraulic cement, rubber, and solidmineral aggregate filler.

2. A floor and deck covering according to claim 1 in which said releaselayer comprises as the major constituent upon setting up a hydratedinorganic cementitious material selected from the group consisting ofgypsum, lime and hydraulic cement.

3. A floor and deck covering according to claim 2 in wlhich said releasecoat contains a finely divided inorganic fi ler.

4. A floor and deck covering according to claim 1 in which there is arelatively thin waterproofing layer between said wear layer and saidrelease layer, said waterproofing layer comprising a textile fabricimpregnated with rubber.

5. A floor and deck covering according to claim 1 including as the toplayer a composition having as its major constituent a vinyl resin.

6. A traffic-bearing composite floor and deck covering which permitsrelative movement between the wear surface thereof and the supportingsub-floor, whereby said Wear surface is not subjected to damagingstresses due to normal movement of the sub-floor, comprising arelatively thin release layer capable of being ruptured when subjectedto stresses created by relative movement between said sub-fioor and saidwear surface to isolate said wear surface from the movement of saidsub-floor applied as a plastic mass over a sub-floor so as to besubstantially coextensive therewith and which upon setting forms asubstantially non-tacky, solid layer having an indentationcharacteristic of less than about 50% four hours after application and ashear strength of not more than about 2.5 p.s.i. seven days afterapplication, said release layer comprising as the major constituent uponsetting a hydrated inorganic cementitious material selected from thegroup consisting of gypsum, lime and hydraulic cement and containing ananionic surface active agent, the weight ratio of inorganic cementitiousmaterial prior to hydration to anionic surface active agent being in therange between about 6:1 and about 20:1, and a relatively thicker wearlayer over said release layer which is applied as a plastic mass andupon setting comprises hydrated hydraulic ce ment, rubber, and solidmineral aggregate filler.

7. A floor and deck covering according to claim 6 in which said releaselayer contains finely divided inorganic filler.

8. A floor and deck covering according to claim 6 in which there is arelatively thin waterproofing layer between said Wear layer and saidrelease layer, said waterproofing layer comprising a textile fabricimpregnated with rubber.

9. A floor and deck covering according to claim 6 including as the toplayer a composition having as its major constituent a vinyl resin.

10. A floor and deck covering according to claim 6, in which saidsurface active agent is selected from the group consisting of alkyl andalkyl aryl sulfonates of the formula RSO X where R is alkyl containingfrom 8 to 20 carbon atoms and alkyl aryl containing from 12 to 20 carbonatoms and X is hydrogen, alkali and alkaline earth metal; and salts offatty acids of the formula R'COOX' where R is alkyl containing from 8 to18 carbon atoms and X is hydrogen, alkali and alkaline earth metal 11. Afloor and deck covering according to claim 10 wherein said anionicsurface active agent comprises sodium lauryl sulfate.

References Cited UNITED STATES PATENTS 2,593,492 4/1952 Scripture 106-902,672,793 3/1954 Rowe et al. 106-90 2,793,129 5/1957 Klein 106-902,877,135 3/1959 Schwarzwalder et a1. 117-70 3,008,843 11/1961 Jolly106-90 3,190,762 6/1965 Carlson et al 106-90 ALFRED L. LEAVITT, PrimaryExaminer.

A. H. ROSENSTEIN, Assistant Examiner.

1. A TRAFFIC-BEARING COMPOSITE FLOOR AND DECK COVERING WHICH PERMITSRELATIVE MOVEMENT BETWEEN THE WEAR SURFACE THEREOF AND THE SUPPORTINGSUB-FLOOR, WHEREBY SAID WEAR SURFACE IS NOT SUBJECTED TO DAMAGINGSTRESSES DUE TO MOVEMENT OF THE SUB-FLOOR, COMPRISING A RELATIVELY THINRELEASE LAYER CAPABLE OF BEING RUPTURED WHEN SUBJECTED TO STRESSESCREATED BY RELATIVE MOVEMENT BETWEEN SAID SUBFLOOR AND SAID WEAR SURFACETO ISOLATE SAID WEAR SURFACE FROM THE MOVEMENT OF SAID SUB-FLOOR APPLIEDAS A PLASTIC MASS OVER A SUB-FLOOR SO AS TO BE SUBSTANTIALLY COEXTENSIVETHEREWITH AND WHICH UPON SETTING FORMS A SUBSTANTIALLY NON-TACKY, SOLIDLAYER HAVING AN INDENTATION CHARACTERISTIC OF LESS THAN ABOUT 50% FOURHOURS AFTER APPLICATION AND A SHEAR STRENGTH OF NOT MORE THAN ABOUT 2.5P.S.I., SEVEN DAYS AFTER APPLICATION, AND A RELATIVELY THICKER WEARLAYER OVER SAID RELEASE LAYER WHICH IS APPLIED AS A PLASTIC MASS ANDUPON SETTING COMPRISES HYDRATED HYDRAULIC CEMENT, RUBBER, AND SOLIDMINERAL AGGREGATE FILLER.